Elastic braid constructions



April 25, 1967 L. COHEN 3,315,559

ELASTIC BRAID CONSTRUGTIONS Filed June 10, 1964 5 Sheets-Sheet 1 INVENTOR LESTER COHEN BY$ w AT TOR NEY April 25, 1967 L. COHEN 3,315,559

ELASTIC B RAID CONSTRUCTIONS 3 Sheets-Sheet 2 INVENTOR LESTER COHEN WWM tww ATTORNEYS April 25, 1967 co N ELASTIC BRAID CONSTRUGTIONS 3 Sheets-Sheet 5 Filed June 10, 1964 FIG. 5

FIG. 4

FIG

m H MO WC m T 8 E L ATTORNEYS United States Patent 3,315,559 ELASTIC BRAD) CONSTRUCTIONS Lester Cohen, Providence, R.I., assignor to International Stretch Products, Inc., New York, N.Y., a corporation of Delaware Filed June 10, 1964, Ser. No. 374,083 8 Claims. (Cl. 87-2) The present invention relates to elastic braid constructions and materials, and more particularly to novel and improved elastic ibraid materials incorporating, as a significant component, monofilament polymer plastics, particularly monofilament polypropylene.

In the construction of elastic and other fabric forms, it has been proposed heretofore to utilize monofilament polymers as a component of the fabric. Polypropylene has proven to have particular advantages for fabric applications for a number of reasons, including cost factors, ease of handling, desirable appearance and general compatibility of its characteristics for fabric use. The present invention is directed specifically to novel and particularly advantageous elastic braids, in which weft elements of the braid are formed entirely or in significant part of polypropylene monofilament. The resulting elastic braid has significant advantages over similar elastic braids utilizing conventional constructions.

As a generality, the new braid construction is more economical to produce, yet is stronger, more shrink resistant, and less subject to curling than a corresponding fabric of conventional construction. Further, the new elastic is lighter in weight, has a lighter, airier appearance, and has fast drying characteristics.

In the new braid construction of the invention, the polypropylene monofilament is so incorporated in the fabric structure as to enhance the elastic action of the fabric in a warpwise, or lengthwise, direction. In addition, the polypropylene monofilament, having desired characteristics of stiffness, serves to maintain the individual elastic warp elements in desired spaced relation, with greater warp separation than could otherwise be achieved with a corresponding amount of weft material. At the same time, the monofilament weft elements serve to maintain the elastic material substantially flat across its entire width, imparting significant desirable resistance to curling at the edges, even when the elastic braid is under substantial elongation. Because of the ability of the monofilament polypropylene to maintain desired separation of the elastic elements with relatively minimum amounts of weft material, the finished braid has a very light and airy appearance, particularly when utilizing clear transparent monofilament in conjunction with whitish elastic warp elements.

In one of the particularly significant forms of the invention, the monofilament polypropylene weft elements are interbraided in running pairs, and conventional multifilament yarns (e.g., rayon) of a sutiable dye shade are interspersed as weft elements between the pairs of monofilaments. The multifilament yarns are distributed in a predetermined manner throughout the braided fabric and serve to impart a desired overall color appearance thereto, The last-described form of the invention is particularly desirable for incorporation into -a garment, as an elastic edging, in a manner such that the elastic element is exposed in thefinished garment, the interspersed multifilament rayon threads imparting not only a desired color to the braid, for matching or harmonizing with the main body of the garment, but also improving the feel of the braid against the skin. Further, the braid structure desirably utilizes running pairs of monofilaments, in place of individual, larger monofilaments, to avoid exposure to the skin of stifier monofilament ends, at locations where the monofilament is severed.

3,315,559 Patented Apr. 25, 1967 The above-described form of braid, which may be re ferred to herein as an external braid because of its exposure to the eye and skin in its intended applications, derives its primary coloring from the multifilament weft yarns interspersed with the polypropylene monofilament, and secondarily from the influence of the elastic warp elements, typically whitish rubber threads, and also to some degree from the clear transparent monofilaments themselves. As a result, as the elastics increase in width, assuming approximately constant fabric density per unit of width, the relative influence of the monofilament and elastic elements on the overall color of the elastic braid tends to decrease so that, all things being equal, elastic braids of increasing width will have progressively darker color appearance. Accordingly, it is one of the more specific aspects of the invention to provide elastic braids of various sizes incorporating uniformly colored multifilament weft elements, clear monofilament weft elements, and uniformly differently colored elastic warp elements, in which the proportion of colored weft elements to clear monofilament weft elements is decreased with increasing widths of elastic braid material, such that the overall color appearance of braids of different width is substantially the same. It will be understood, in this respect, that the same end result could be achieved by utilizing lighter colored multifilament weft elements in the Wider braid constructions. However, it is particularly desirable from economic and production standards to utilize dyed yarns from the same dye lot, and achieve color uniformity by varying the proportion of dyed weft elements to clear weft elements and to warp elements. This aspect of the invention becomes particularly important in garment constructions in which it is desired to incorporate in the same garment lboth wide and narrow external braids.

In a second advantageous form of the invention, which is designed particularly as an internal braid, although not necessarily limited to internal applications, the warp elements in the braid are formed of elastic rubber threads, desirably of a whitish hue, and the interbraided weft elements are formed entirely of monofilament polypropylene. In a typical internal braid construction, the polypropylene monofilament may be of a heavier, stifier na ture than that utilized in the external braid, because the internal ibraid is encased within a hem of a garment, for example, which obviates conditions which otherwise might arise with regard to contacting of the skin by ends of the heavier monofilament. The internal braid construction being formed entirelyof rubber warp elements and monofilament weft elements has especially good drying characteristics and acid resistance and therefore is particularly suitable for such applications as infants pants.

One of the particularly advantageous features of the new braid constructions resides in the fact that the polypropylene monofilament exerts a significant and advantageous gripping action upon the rubber warp elements, substantially minimizing the tendency for the rubber warp elements, which are incorporated into the braid under predetermined initial tension, from withdrawing into the braid material at the cut ends. A further advantageous feature of the new braid constructions resides in the fact that, although the polypropylene weft elements are more expensive in character than conventional weft yarns, equivalent elastic construction is obtained using a looser construction, with sufficiently reduced amounts of polypropylene being required per yard of the finished braid to bring about an actual cost reduction in the finished material. The new braid constructions have also particularly advantageous abrasion resistance characteristics. Even with respect to the external braid materials, which utilize some multifilament rayon weft elements, the re- 'warp. elements.

matenal, mo st advantageously polypropylene.

pairs of polypropylene monofilament.

' weft elements are formed of multifilament yarns, advanitageously rayon, and in the specific braid structure dis- 7 closed, nine'individual yarns of multifilament rayon are 7 provided, interspersed relatively equally with the mono- I sistance to abrasion and other deterioration is improved,

since the presence of the monofilament weft elements appears to afford some protection for the multifilament yarns. I v

For a better understanding of the invention, reference should be made, to the following detailed description and to the accompanying drawing,'in which:

FIG. 1 is an enlarged photographic illustration of the new external braid construction in plan view, with the braid being shown under a predetermined applied tension to facilitate illustration of its component elements;

FIG. 2 is an enlargedphotographic illustration of a braid similar to that of FIG. 1, although of somewhat greater Width;

' FIG. 3 is a simplified representation of a section of garment incorporating ela'stic braid elements of the type illustrated in FIGS. 1 and 2; and 7 FIGS. 4 and 5 are plan views of an internal braid construction according to the invention, illustrating the braid in relaxed and tensioned conditions, respectively- Referring'now to the drawing, and initially to FIG. 1, there is shown an elastic braid constructed in accordance with the invention and suitable particularly as an elastic V edging fora garment. The braid includes a plurality of elastic warp elements 10, which extend lengthwise of the braided strip in substantially straight, generally parallel an elastic edging having a relaxed width of about A inch. The elastic warp elements 10, which are normally incorporated into the braided strip under a condition of predetermined initial tension, are advantageously formed of v V barerubber threads.

Interbraided with the rubber warp elements 10, as by means of conventional braiding machines, are a plurality of weft elements 11, 12, the total number of weft elements typically numbering 2N+ 1, for a given number (N )"of As illustrated in FIG. 1, the weft elements 11," 12 course alternately under and over adjacent ofFIG. 1 is shown to be extended in length on the order of 100, percent or more, in which condition the weft larger angle tothe warp, and the individual weft elements are packed together more closely in a warpwise direction.

In accordance with a specific and significant aspect" of the invention, atleast a substantial portion of the weft elements'is'comprised of a monofilament polymer plastic In the form of the'inveution illustrated in FIG. 1, the polypropylene Weft elements, identified by the reference numeral 12, comprise running pairs of individual monofilaments.

v at the point designated A in FIG. 1, and for a complete warp elements and extend from one side tothe' other of V 'thebraided strip. a 7 For convenience of illustration, the elastic braided strip elements extend across the braided strip at an angle of; [about 45;to the warp elements. However, as will be understood, in the relaxed condition of the braid, the ;weft elements extend across the warp elements at a much;

1 In addition, in the illustrated, extended condition of the strip, the \m'dth thereof between outside warp elements In other words, each weft element 12 comprises a side 'by-side runningrpair of monofilaments which are intermerits and seventeen weft elements, there are advan-.-

tageously about eight Weft elements comprising running The remaining filament weftelements. By way of example, commencing braiding cycle, up to the point B, weft elements are ina corporated in the following order, considering those yarns.

extending upward from right to left: 2 rayon (R), 1 polypropylene pair (P), lR, 2P, 2R, 1P, 1R, 2P, 2R, 1P,-

1R, 1P. Advantageously, occasional weft elements, such as every third multifilament element, are looped out beyond the principal edge of the strip, as indicated at 13, forming loops. V

The elastic braid illustrated in FIG. '1 is intended particularly for external use as a garment edging, for example, in which the elastic braid may be placed directly against the skin of the wearer of the garment. For this reason, it is desirable and advantageous to utilize running pairs of polypropylene monofilaments rather than individual monofilaments of correspondingly largersize.v V In addition, it is desirable to incorporate an appropriate proportion of multifilament yarns, of rayon or other suitable material, both to provide for an improved feel of'the'braid against the skin and also to provide for a desired outward appearance.

In a specific advantageous elastic braid according to the invention and as illustrated in FIG. 1, the rubber warp elements may be of a size on the order of 48 gauge, while the individual monofilaments of the running pairs may be of a size on the order of 70 denier. The individual multifilament yarns may be of a 450 denier, for example.

A desired color effect is achieved by utilizing in con-.

junction with the clear, transparent monofilament elements 12, a rubber warp element of whitish hue, and multifilament yarnsof a predetermined dyed color. The dye shade of the rnultifilament yarns strongly predominates and determines the basic color of'the braided strip. It

should be understood, however, that the monofilament Q 7 elements themselves may be colored where desirable or expedient.

twelve warp ends'in the form of individual elementsgfl of elastic rubber;

and interspersed elements of multifilament rayon yarn,

substantially as described in {connection with" the nar-i rower braid of- FIG. 1, the sizes and other characteristics V of the individual warp and weftcomponentsjbeing the same as described for FIG. 1 for V V companion braided strip materials; a

" As illustrated .in' FIG. 2, forpur-poses of clarity,rthe half-inch elasticbraid is" extended on the order of percent, causing its width to ber educed to about threeeighths of an inch an d its weft elements to be disposed. V at about 45 to the warp. In the relaxedrnateriah'the weft yarnswouldfbe more closely packed and would extend'at a larger angle 'to'the' warp, as in the case of r the narrowerbraid ofFlG. 1. In addition, occasional" .weft elements, such as alternate ones of the multifilament rayon elements, 'are looped out at the edge, as at 23.

. As will be understood, it is often desirable to} incorporate into a single garmentelastic edging strips of dif ferent widths. By way'of specific. example, -in.the gar- I j ment 30 illustrated in FIG. 3, it may be desirable to incorporate as an elastic waistband 31 the wider elastic braid of FIG. 2, and as an elastic leg band32 the narrower elastic braid of 'FIG. 1. sirable and advantageous for the individual elastic bands size on the order of V The weft elements 21,,22 are com prised of running pairs'ofpolypropylene mon'ofilameritf Insuch a case, it is de- 7 v 31, 32 tohave the same overall color shade, to match 7 or harmonize with the body fabric of the garment 30. accordance with one specific aspect of thefinvem tion, color shade matching between elastic braids of the V new construction and of varying widths is accomplished by effecting a proper proportioning of'the' dyed multifilament elements to the clear monofilament elements and to the whitish rubber warp elements. In this connection, it has been established that the color dominance of the dyed multifilament weft elements increases with the increasing widths of the elastic braid. Accordingly, in order to provide substantially color matched elastic braids of different width, utilizing multifilament weft elements of the same dye lot and utilizing components of an otherwise corresponding nature, it is necessary in accordance with the invention to decrease the proportion of dyed multifilament weft elements to the monofilament weft elements.

Thus, in the wider elastic braid of FIG. 2, which advantageously incorporates twelve warp elements and twenty-five (2N+1) weft elements, there are advantageously ten multifilament weft elements and fifteen monofilament weft elements, each of the latter elements consisting of a running pair of monofilaments. Thus, in the half-inch elastic braid, the ratio of multifilament to monofilament weft elements is 2:3, whereas the ratio is about 1:1 (actually 9:8) in the case of the 75 inch material. The ratio of multifilament weft elements to warp elements is less dissimilar in each case, being 10:12 in the case of the half-inch braid and 9:8 in the case of the 54 inch braid.

In the wider elastic braid of FIG. 2, the multifilament and monofilament weft elements are relatively uniformly interspersed. By way of specific illustration, in a complete braiding cycle, reading from point C to point D in FIG. 2, the weft element sextending upward to the left appear in the following order: 1 multifilament rayon (R), 1 running pair of polypropylene monofilament (P), 1R, 2P, etc., the foregoing series being repeated 5 times for a total of weft elements.

In the form of the invention illustrated in FIG. 4 (relaxed) and FIG. 5 (extended approximately 100 percent), the elastic braid is constructed entirely of rubber warp elements and monofilament polyproylene weft elements 41. Advantageously, in a typical ,56 inch elastic braid, there are eight (N) ends of rubber warp elements, advantageously of a size on the order of 37 gauge, and seventeen (2N +1) separate weft elements, each consisting of a monofilament polypropylene of a size on the order of 150 denier. The polypropylene monofilaments are interbraided alternately over and under adjacent weft elements 40 in a conventional manner, but in a way to provide a wholly novel and unconventional braided structure.

Although its uses are not necessarily so limited, the elastic braid of FIGS. 4 and 5 is adapted particularly for internal applications in which the braid is encased within a suitable hem or the like of a garment. In such cases, it is desirable or appropriate to utilize heavier (e.g., 150 denier) individual monofilament weft elements, rather than running pairs of smaller weft elements as in the braid constructions of FIGS. 1 and 2. In this connection, an occasional broken or cut end of the monofilament may tend to project out of the braid structure, and this could cause some discomfort in the case of monofilaments of the heavier deniers, if utilized for external applications in which the braid was placed directly against the skin. This is a matter of little or no concern, however, where the braid is to .be incorporated within a hem or other protective layer.

The form of the invention illustrated in FIGS. 4 and 5 is wholly comprised of monofilament, non-cellulosic braid elements which, on the one hand, renders the braid extremely fast drying and, on the other hand, makes it particularly resistant to attack by acids, which makes the elastic braided product particularly desirable for incorporation in baby pants, for example, where the foregoing characteristics are particularly important.

In either of its described forms, the elastic braid of the invention has significant economic and practical advantages. Thus, although the braided structures of the invention utilize generally more costly components than conventional braids, corresponding elastic structures are obtainable utilizing looser weaves and involving smaller amounts of material per running yard of the braid so that an overall cost reduction is realized.

The use of monofilaments to form all or a substantial portion of the weft elements of the braid structure provides a product which is very light and airy and is particularly attractive and appealing to the eye. This is realized in part by the inherent ability of the polypropylene weft elements to maintain the individual elastic warp elements in relatively widely separated relation and to a much greater extent than possible using an equal proportion of weft materials in a corresponding braid of conventional construction. Moreover, the relativestiifness of the monofilament polypropylene imparts a significantly improved curl resistance to the braided strip, so that it retains its desired flat form, even under tension, a factor which results in greater comfort to the user and a more desirable appearance.

A further substantial advantage of the new structure utilizing polypropylene monofilaments in combination with bare rubber elastic warp elements, resides in the surprising and substantial gripping action between the monofilament and the rubber wrap elements, such that, when the braid is cut, the warp elements, which are incorporated into the braid under an initial tension, do not retract or withdraw significantly from the end of the braided strip as is commonly experienced with braids of more conventional construction. In addition, the physical characteristics of the monofilament are such that, when the monofilament is incorporated by braiding into the elastic structure, extension of the braid is accompanied by torsional flexing of the monofilament elements. This action imparts an additional measure of warpwise elasticity to the overall structure, enhancing the elastic action of the rubber warp elements.

A further advantage of the new braid construction resides in its substantial durability and resistance to abrasion, which appears to be derived substantially from the characteristics of the polypropylene monofilament as incorporated in the overall new structure. The significantly increased durability and abrasion resistance is realized even in the form of the invention illustrated in FIGS. 1 and 2, which incorporates substantial proportions of multifilament rayon yarns, since the polypropylene monofilaments appear to maintain the general form and structural characteristics of the material, even though the other fibers may have been subjected to some deterioration. In addition to improved abrasion resistance, the new polypropylene-incorporating braid has better strength and elasticity characteristics when wet than conventional braid structures, making the new braid particularly attractive for use in those applications where the elastic may be subjected to wetting or moistening.

It should be understood that the specific forms of the invention herein illustrated and described are intended to be representative only, as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.

I claim:

1. An elastic braid comprising (a) a plurality of elastic warp elements, each consisting of an individual rubber strand,

(b) a first plurality of interbraided weft elements, each consisting of a multifilament thread,

(c) a second plurality of interbraided weft elements,

each including a polypropylene monofilament,

(d) the weft elements being directed alternately over and under adjacent warp elements, and

(e) the polypropylene weft elements supporting the warp elements with flatness and rigidity and at a '(b) a plurality of interbraided weft elements, (c) at least a substantial proportion of the'weft elements each comprising a running pair of monofilaments of clear, transparent polymer plastic material, and V V (d')' multifilament weft elements interbraided with said monofilament pairs, e (e) the proportion of multifilament elements to monofilament pairs being generally in the range of one to one or less. 5. The elastic braid of claim 4, in which (a) the warp elements are of whitish hue, and

V (b) the multifilament elements are of a predetermined dyed color imparting a dominant hue to the braid. 6. A garment comprising,

L (a) .a body panel, a

'(b) a first elastiobraid according to claim secured along one edge' of said panel, and

along another edge of said panel, 7 5 (d) one of said elastic braids being wider than the other, e r (e) said first equivalent warp and weft structure per unit of area, (f) the multifilament weft elements of both braids being of substantially the same hue, and a V (g) the wider braid having a lower proportion of 1 multifilament to monofilament elements than the narrower braid.

and second braids having generally (c) a second elastic braid according'to claim 5 secured 8 V 7. The garment .of claim 6, i.n. which V (a) the wider braid has a relaxe d width on the order of one-half inch and includes about twelve warp elements, about ten multifilament weft elements, and i about fifteen weft elements of monofilament pairs,

and v (b) the narrower braid has a relaxed width on the order of five-sixteenths of an inch and includes about eight warp elements, about nine multi-filament weft elements, and about eight weft elements of monofilament pairs. 8. An elastic braid comprising (a) a plurality of spaced, generally parallel; longitw' dinally extending elastic warp elements, and

(b) a plurality of interbraided weft elements extending from one side to the other of the braid strip and passing alternately over and under adjacent warp elements,

(c) said weft elements being formed of clear, transparent monofilament polymerplastic,

(d) said. before-mentioned weft elements supporting said warpelements'in spaced-apart relation at a distance substantially greater than thethickness of;

the weft elements, 7 7

' (e) said weft elements being comprised in first part of running pairs'of monofilaments and in second part of dyed multifilament yarns, 1

(f) said multifilament yarns being in proportion of '7 9 about one to one or less to themonofilamen-t pairs.

References Cited by tlie Examiner:

UNITED STATES. PATENTS 2,931,398 4/1960 Masters 139- 423 r 2,960,904 11/1960 Semmel 872 3,172,430 3/1965 Weidhaas 139-422 3,199,548 8/l965iConant 139.421C

FRANK J. COHEN, Primary Examiner.

I. PETRAKES, Assistant Examiner. 5

Bellmore 139 421 X" 

8. AN ELASTIC BRAID COMPRISING (A) A PLURALITY OF SPACED, GENERALLY PARALLEL, LONGITUDINALLY EXTENDING ELASTIC WRAP ELEMENTS, AND (B) A PLURALITY OF INTERBRAIDED WEFT ELEMENTS EXTENDING FROM ONE SIDE TO THE OTHER OF THE BRAID STRIP AND PASSING ALTERNATELY OVER AND UNDER ADJACENT WARP ELEMENTS, (C) SAID WEFT ELEMENTS BEING FORMED OF CLEAR, TRANSPARENT MONOFILAMENT POLYMER PLASTIC, (D) SAID BEFORE-MENTIONED WEFT ELEMENTS SUPPORTING SAID WRAP ELEMENTS IN SPACED-APART RELATION AT A DISTANCE SUBSTANTIALLY GREATER THAN THE THICKENSS OF THE WEFT ELEMENTS, (E) SAID WEFT ELEMENTS BEING COMPRISED IN FIRST PART OF RUNNING PAIRS OF MONOFILAMENTS AND IN SECOND PART OF DYED MULTIFILAMENT YARNS, (F) SAID MULTIFILAMENT YARNS BEING IN PROPORTION OF ABOUT ONE TO ONE OR LESS TO THE MONOFILAMENT PAIRS. 